AIRLESS PAINT SPRAYER
SERVICE/OPERATION
MANUAL
AIRLESSCO LP400
ALLPRO 410E
Form No. 001-700 APR07
TABLE OF CONTENTS
Product Diagrams & Parts Lists
Introduction
LP Series Specifications
Safety Warnings
1
2
Getting Started
Flushing
How to Flush
Setting Up
Starting Up
Pressure Relief Procedure
Daily Maintenance
5
5
7
8
10
10
Gear & Pump Assembly
Upper & Lower Piston Rods
Fluid Pump
Frame Assembly Parts List
Suction Assemblies
Repairs/Maintenance Instructions
Spray Gun Operation
Spray Gun Troubleshooting
Spray Tip Selection
Electric Motor Maintenance
Field Troubleshooting
Servicing the Fluid Pump
Servicing Piston Rod,
Outlet Valve
Servicing Suction Assembly
Packing Replacement
Electrical Board Calibration
Electrical Troubleshooting
Replacement of Electrical Components
11
12
13
14
15
16
18
18
19
23
24
25
Manufactured by: AIRLESSCO BY DUROTECH CO.
5397 N. Commerce Ave.,
Moorpark, CA 93021Tel: 805-523-0211 Fax: 805-523-1063
www.airlessco.com email: [email protected]
SUBJECT TO CHANGE WITHOUT NOTICE.
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Copyright © 2007, All rights reserved.
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INTRODUCTION
The LP400/410E delivers the durability of an Airlessco, with the simplicity of a
mechanical pressure control system. It's built on a compact, well balanced
triple chrome plated carry frame sturdy enough to stand on.
It's powered by a dependable fan cooled, totally enclosed DC motor - no
troublesome electronic controls! The heart of any contractor sprayer is the
pump, and the durability of the LP pump is legendary amongst pro painters.
It features the oversized "Slow-Stroking" stainless steel piston, and
Airlessco's patented externally adjustable packing system. It's the only
packing system that has external adjustment of upper and lower packings.
No getting stuck on the job with blown packings and a sprayer full of paint!
The LP400 comes standard with our 008 Silver
Contractor spray gun with built in swivel, and
50' of 1/4" high pressure airless hose.
Specifications
Material Applications
Motor Type
Max Pressure
Max Output
@ Pressure
@ Free Flow
Max Tip Size
Oil Base Coatings
Sealer
Varnish
Water Base Coatings
Solid Stain
.6 HP TEFC DC
3000 PSI
.46 gpm
.5 gpm
.021"
HANDLE THIS UNIT AS YOU WOULD A LOADED FIREARM!
High pressure spray can cause extremely serious injury.
OBSERVE ALL WARNINGS!
Before operating this unit, read and follow all safety warnings and instructions
related to the usage of this equipment on pages 2, 3 & 4. READ, LEARN, and
FOLLOW the Pressure Relief Procedure on Page 10 of this manual.
All Service Procedures to be performed by an Authorized Airlessco Service Center ONLY.
NO MODIFICATIONS or alterations of any AIRLESSCO Equipment or part is allowed.
MANUAL NOTATIONS
WARNING - Alerts user to avoid or correct conditions that could cause bodily injury.
CAUTION - Alerts user to avoid or correct conditions that could cause damage to or destruction of equipment.
IMPORTANT - Alerts users to steps or procedures that are essential to proper equipment repair and maintenance.
NOTE - Identifies essential procedures or extra information.
1
SAFETY WARNINGS
HIGH PRESSURE SPRAY CAN CAUSE EXTREMELY SERIOUS INJURY.
Handle as you would a loaded firearm.
Follow the PRESSURE RELIEF PROCEDURE.
DO NOT USE HALOGENATED SOLVENTS IN THIS SYSTEM.
The prime valve, and most airless guns have aluminum parts and may explode. Cleaning agents, coatings, paints or adhesives
may contain halogenated hydrocarbon solvents. DON'T TAKE CHANCES! Consult your material suppliers to be sure. Some of
the most common of these solvents are: Carbontetrachloride, Chlorobenzene, Dichloroethane, Dichloroethyl Ether,
Ethylbromide, Ethylchloride, Tethrachloethane. Alternate valves and guns are available if you need to use these solvents.
MEDICAL ALERT - Airless Spray Wounds
If any fluid appears to penetrate your skin, get
EMERGENCY MEDICAL CARE AT ONCE.
DO NOT TREAT AS A SIMPLE CUT.
Tell the doctor exactly what fluid was injected.
directly into the blood stream. Consultation with a plastic surgeon
or reconstructive hand surgeon may be advisable.
INJECTION HAZARD
GENERAL PRECAUTIONS
• Fluids under high pressure from spray or leaks can
penetrate the skin and cause extremely serious injury,
including the need for amputation.
• NEVER alter equipment in any manner.
• NEVER point the spray gun at anyone or any part of
the body.
• NEVER spray highly flammable materials.
• NEVER put your hand or fingers over the spray tip. Do
not use a rag or any other materials over your fingers.
Paint will penetrate through these materials & into the hand.
• NEVER allow another person to use sprayer unless
he is thoroughly instructed on its safe use and
given this operators manual to read.
• NEVER try to stop or deflect leaks with your hand or body.
• ALWAYS wear a spray mask, gloves and protective
eye wear while spraying.
• ALWAYS have the tip guard in place when spraying.
• ALWAYS lock the gun trigger when you stop spraying.
• ALWAYS remove tip from the gun to clean it.
• NEVER try to "blow back" paint, this is not an air spray
sprayer.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE
before cleaning or removing the spray tip or servicing any
system equipment.
• Be sure the equipment safety devices are operating properly
before each use.
• Tighten all of the fluid connections before each use.
MEDICAL TREATMENT\
• If any fluid appears to penetrate your skin, get EMERGENCY
CARE AT ONCE! DON'T TREAT AS A SIMPLE CUT.
• Go to an emergency room immediately.
• Tell the doctor you suspect an injection injury.
• Tell him what kind of material you were spraying with
and have him read NOTE TO PHYSICIAN above.
2
NOTE TO PHYSICIAN: Injection in the skin is a traumatic
injury. It is important to treat the injury surgically as
soon as possible. DO NOT DELAY treatment to research
toxicity. Toxicity is a concern with some exotic coatings injected
• NEVER smoke while in spraying area.
• NEVER use around children.
• ALWAYS ensure fire extinquishing equipment is
readily available and properly maintained.
NEVER LEAVE SPRAYER UNATTENDED
WITH PRESSURE IN THE SYSTEM.
FOLLOW PRESSURE RELIEF
PROCEDURES.
NOTE: United States Government safety
standards have been adopted under the
Occupational Safety & Health Act. These
standards, particularly the General Standards,
Part 1910 & Construction Standards, Part 1926
should be consulted.
SAFETY WARNINGS
ALWAYS INSPECT SPRAYING AREA
HOSES
• Keep the spraying area free from obstructions.
• Tighten all of the fluid connections securely before each
use. High pressure fluid can dislodge a loose coupling or
allow high pressure spray to be emitted from the coupling
and result in an injection injury or serious bodily injury.
• Make sure the spraying area has good ventilation
to safely remove vapors and mists.
• NEVER keep flammable material in spraying area.
• NEVER spray in vicinity of open flame or other
sources of ignition.
• The spraying area must be at least 20 ft. away from
spray unit.
SPRAY GUN SAFETY
• ALWAYS set gun safety lock in the "LOCKED"
position when not in use & before servicing or cleaning.
• NEVER remove or modify any part of the gun.
• ALWAYS REMOVE THE SPRAY TIP when cleaning.
Flush unit at the LOWEST POSSIBLE PRESSURE.
• ALWAYS check operation of all gun safety devices
before each use.
• Be very careful when removing the spray tip or hose
from the gun. A plugged line will contain fluid under
pressure. If the tip or line is plugged, follow the
PRESSURE RELIEF PROCEDURE.
TIP GUARD
• ALWAYS have the tip guard in place on the spray
gun while spraying. The tip guard alerts you to the
injection hazard and helps prevent accidentally
placing your fingers or any part of your body close
to the spray tip.
SPRAY TIP SAFETY
• Use extreme caution when cleaning or changing
spray tips. If the spray tip clogs while spraying, engage the gun safety latch immediately. ALWAYS
follow the PRESSURE RELIEF PROCEDURE
and then remove the spray tip to clean it.
• NEVER wipe off build up around the spray tip.
TOXIC FLUID HAZARD
• ALWAYS remove tip guard & tip to clean AFTER
pump is turned off and the pressure is relieved by
following the PRESSURE RELIEF PROCEDURE.
• Hazardous fluid or toxic fumes can cause serious injury
or death if splashed in eyes or on skin, inhaled or
swallowed. Know the hazards of the fluid you are using.
Store & dispose of hazardous fluid according to
manufacturer, local, state & national guidelines.
• ALWAYS wear protective eyewear, gloves,
clothing and respirator as recommended by fluid
manufacturer.
• Only use hoses with a spring guard. The spring guard
helps protect the hose from kinks or other damage which
could result in hose rupture and cause an injection injury.
• NEVER use a damaged hose, which can result in hose
failure or rupture and cause an injection injury or other
serious bodily injury or property damage. Before each use,
check entire hose for cuts, leaks, abrasions, bulging of the
cover, or damage or movement of couplings. If any of
these conditions exist, replace the hose immediately.
• NEVER use tape or any device to try to mend the hose as
it cannot contain the high pressure fluid. NEVER
ATTEMPT TO RECOUPLE THE HOSE. A high pressure
hose is not recoupleable.
GROUNDING
• Ground the sprayer & other components in the system to
reduce the risk of static sparking, fire or explosion which
can result in serious bodily injury and property damage.
For detailed instructions on how to ground, check your
local electrical code.
• ALWAYS ensure switch is in OFF position before
plugging unit in.
Always Ground All of These Components:
1. Sprayer: plug the power supply cord, or extension cord,
each equipped with an undamaged three-prong plug, into a
properly grounded outlet. DO NOT USE AN ADAPTER.
Use only a 3 wire extension cord that has a 3 blade
grounding plug, and a 3 slot receptacle that will accept
the plug on the product. Make sure your extension cord is
in good condition. When using an extension cord, be sure to
use one heavy enough to carry the current your product will
draw. (Note: The table on the top of the next page shows
the correct size to use depending on cord length and name
plate ampere rating. If in doubt, use the next heavier gauge.
The smaller the gauge number, the heavier the cord.)
2. Fluid hose: use only grounded hoses.
3. Spray gun or dispensing valve: grounding is obtained
through connection to a properly grounded fluid hose and
pump.
4. Object being sprayed: according to your local code.
5. All solvent pails used when flushing.
• Once each week, check electrical resistance of hose (when
using multiple hose assemblies, check overall resistance.)
Overall (end to end) resistance of unpressurized hose must
not exceed 29 megohms (max.) for any coupled length or
combination of hose lengths. If hose exceeds these limits,
replace it immediately.
• Never exceed 500 ft. (150 m) overall combined cord
length to assure electrical continuity.
3
SAFETY WARNINGS
UL RECOMMENDATION FOR MINIMUM GAUGE EXTENSION CORD
AMPERAGE
RATING
RANGE
5-6
6-8
8 - 10
10 - 12
VOLTAGE
120
120
120
120
LENGTH OF CORD IN FEET
25
50
100
150
200
250
300
400
500
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12
12
10
12
10
10
8
10
10
8
8
10
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8
6
8
6
6
6
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6
4
6
6
4
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Always Follow Recommended Pressure
and Operating Instructions
KEEP CLEAR OF MOVING PARTS
Keep clear of moving parts when starting or operating the
sprayer. Do not put your fingers into any openings to avoid
amputation by moving parts or burns on hot parts. Precaution
is the best insurance against an accident. When starting the
motor, maintain a safe distance from moving parts of the equipment. Before adjusting or servicing any mechanical part of the
sprayer, follow the PRESSURE RELIEF PROCEDURE.
AVOID COMPONENT RUPTURE
• This sprayer operates at 3000 psi (205 bar). Always be
sure that all components and accessories have a maximum
working pressure of at least 3000 psi to avoid rupture
which can result in serious bodily injury including
injection and property damage.
• NEVER leave a pressurized sprayer unattended to avoid
accidental operation of it, which could result in serious
bodily injury.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE
whenever you stop spraying and before adjusting,
removing or repairing any part of the sprayer.
• NEVER alter or modify any part of the equipment to
avoid possible component rupture which could result in
serious bodily injury and property damage.
• NEVER use weak, damaged, or non-conductive paint
hose. Do not allow kinking or crushing of hoses or
allow it to vibrate against rough, sharp or hot surfaces.
Before each use, check your hoses for damage and wear
and ensure all of the fluid connections are secure.
• ALWAYS replace any damaged hose. NEVER use tape
or any device to mend the hose.
• NEVER attempt to stop any leakage in the line or
fittings with your hand or any part of the body. Turn off
the unit and release pressure by following PRESSURE
RELIEF PROCEDURE.
• ALWAYS use approved high pressure fittings and
replacement parts.
• ALWAYS ensure fire extinquishing equipment is readily
available and properly maintained.
PREVENT STATIC SPARKING FIRE/EXPLOSIONS
• ALWAYS be sure all of the equipment & objects being
sprayed are properly grounded. Always ground sprayer,
paint bucket and object being sprayed. See the grounding
section of this manual for grounding information.
• Vapors created when spraying can be ignited by sparks.
To reduce the risk of fire, always locate the sprayer at
least 20 feet (6 m.) away from spray area. Do not plug in
or unplug any electrical cords in the spray area. Doing so
can cause sparks which can ignite any vapors still in the
air. Follow the coating & solvent manufacturers safety
warnings and precautions.
• Use only conductive fluid hoses for airless applications.
Be sure the gun is grounded through the hose connections.
Check ground continuity in hose & equipment. Overall
(end to end) resistance of unpressurized hose must not
exceed 29 megohms for any coupled length or combination
of hose length. Use only high pressure airless hoses with
static wire approved for 3000 psi.
FLUSHING
• Reduce the risk of injection injury, static sparking or
splashing by following the specific cleaning process.
• ALWAYS follow the PRESSURE RELIEF PROCEDURE.
• ALWAYS remove the spray tip before flushing. Hold
the metal part of the gun firmly to the side of a metal pail
& use the lowest possible fluid pressure during flushing.
• NEVER use cleaning solvents with flash points below
140 degrees F. Some of these are: acetone, benzene,
ether, gasoline, naptha. Consult your supplier to be sure.
• NEVER SMOKE in the spraying/cleaning area.
WHEN SPRAYING & CLEANING WITH FLAMMABLE PAINTS AND THINNERS
1. When spraying with flammable liquids, the unit must be located a minimum of 25 feet away from the spraying area in a
well ventilated area. Ventilation must be sufficient enough to prevent the accumulation of vapors.
2. To eliminate electrostatic discharge, ground the spray unit, paint bucket & spraying object. See GROUNDING. Use only
high pressure airless hoses approved for 3000 psi which is conductive.
3. Remove the spray tip before flushing. Hold the metal part of the gun firmly to the side of a metal pail & use the lowest
possible fluid pressure during flushing.
4. Never use high pressure in the cleaning process. USE MINIMUM PRESSURE.
5. Do not smoke in spraying/cleaning area.
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FLUSHING
1. New Sprayer
5. Storage
Your sprayer was factory tested in an oil solution which
was left in the pump. Before using oil-base paint, flush
with mineral spirits only. Before using water-base paint
flush with mineral spirits, followed by soapy water, then a
clean water flush.
Always relieve pressure (See pressure relief
procedure on page 10) prior to storage or when
machine is unattended.
2. Changing Colors
Flush with a compatible solvent such as mineral spirits or
water.
3. Changing from water-base to
oil-base paint.
Flush with soapy water, then mineral spirits.
4. Changing from oil-base to
water-base paint.
Flush with mineral spirits, followed by soapy water, then a
clean water flush.
Oil-base Paint: Flush with mineral spirits. Ensure that
there is no pressure in the unit, then close the prime/
pressure relief valve.
Water-base Paint: Flush with water, then mineral spirits.
For longer term storage use a 50/50 mixture of mineral
spirits and motor oil. Always ensure that there is no pressure in the unit, and close the prime/pressure relief valve
for storage.
6. Start-up after storage
Before using water-base paint, flush with soapy
water and then a clean water flush.
When using oil-base paint, flush out the mineral
spirits with the material to be sprayed.
NEVER leave pump unattended
while under pressure!
HOW TO FLUSH
FIGURE 1
FIGURE 2
Prime/Pressure Relief Valve (Prime/PR Valve)
Used to relieve pressure from gun, hose & tip and to prime
the unit when in OPEN position.
(It is in open position
when there is a wider gap
between valve handle and
cam body).
When valve is in the CLOSED
position, there is only a very
slight gap between handle & body.
When closed the system is
pressurized.
Handle as a Loaded Firearm!
PRESSURE CONTROL KNOB. (FIG. 2)
Used to adjust pressure. Turn clockwise (CW) to increase
pressure and counterclockwise (CCW) to decrease pressure.
FIGURE 3
TOGGLE
SWITCH
Continued on next page............
5
HOW TO FLUSH (continued)
1. Be sure the gun safety latch is engaged and there
is no spray tip in the gun. Refer to page 14 on how
to lock the safety latch and the gun's safety features.
FIGURE 4
REMOVE SPRAY TIP.
ENGAGE GUN SAFETY
LATCH.
2. Pour enough clean, compatible solvent into a large,
empty metal pail to fill the pump and hoses.
3. Place the suction tube into the pail.
4. Turn the Prime/Pressure Relief (PR) Valve to the
"OPEN" , priming position. Refer to Figure 1.
5. Point the gun into the metal pail and hold a metal
part of the gun firmly against the pail. Refer to Figure 5.
To reduce the risk of static sparking
which can cause fire or explosion,
always hold a metal part of the gun firmly
against the metal pail when flushing. This
also reduces splashing.
FIGURE 5
MAINTAIN FIRM
METAL TO METAL
CONTACT BETWEEN
GUN AND CONTAINER
6
6. Disengage the gun safety latch and squeeze the
gun trigger. Turn the ON-OFF Toggle Switch to the
"ON" position (Figure 3) and turn Pressure Control
Knob (Figure 2) clockwise to increase pressure just
enough to start the pump.
7. Turn the Prime/PR Valve to the PRESSURE
"CLOSED" position. This will allow solvent to be
flushed through the pump, hoses and gun. Allow the
unit to operate until clean solvent comes from the gun.
8. Release the trigger and engage the gun safety
latch.
9. Whenever you shut off the sprayer, follow the
"PRESSURE RELIEF PROCEDURE".
SETTING UP
1. Connect the hose and gun.
a. Remove the plastic cap plug from the outlet tee
and screw a conductive or grounded 3000 psi
airless spray hose onto fluid outlet.
b. Connect an airless spray gun to the other end of
the hose.
c. Do not use steel braided airless hose. Use nylon
braided airless hose only.
NOTE: Do not use thread sealer on swivel
unions as they are made to self-seal.
Use thread seal on tapered male threads only.
2. Fill the packing nut/wet cup with
5 drops of Airlessco Throat Seal
Oil (TSO). See (Figure 6).
FIGURE 6
3. Check the electrical service.
Be sure the electrical service is 120 VAC, 15 amp
minimum, and that the outlet you use is properly
grounded.
4. Grounding
WARNING
To reduce the risk of static sparking, fire or
explosion which can result in serious bodily
injury and property damage, always ground
the sprayer and system components and the
object being sprayed, as instructed in the
safety warning section of this manual.
5. Flush the sprayer
As per "Flushing Procedure" in this manual.
7
STARTING UP
1. Learn the functions of the controls.
PRIME/PRESSURE (PR) RELIEF VALVE is used to
prime pump and to relieve pressure from gun, hose and tip.
2. Prepare the material
a. Prepare the material according to the material
manufacturer's recommendations.
b. Place the suction tube into the material
container.
FIGURE 7
Prime/Pressure Relief Valve (Prime/PR Valve)
Used to relieve pressure from gun, hose & tip and to prime
the unit when in OPEN position. (It is in open position
when there is a wider gap
between valve handle and
cam body)
When in CLOSED position,
there is only a very slight gap
between handle & body.
When closed the system is
pressurized. Handle as a loaded firearm!
3. Starting the sprayer
(See Figure 7, 8 & 9)
a. Prime/PR Valve must be "OPEN" in the priming
position.
b. When you have ensured that the gun safety latch is
engaged, attach tip and safety guard.
c. Turn the ON-OFF Toggle Switch to the
"ON" position.
d. After the pump is primed, turn Prime/PR Valve to
the "Closed" position.
FIGURE 8
e. Turn Pressure Control Knob to the desired spray
pressure.
TOGGLE
SWITCH
PRESSURE CONTROL KNOB is used to adjust
pressure. Turn clockwise (CW) to increase pressure and
counterclockwise (CCW) to decrease pressure.
FIGURE 9
8
f. Disengage the gun safety latch and you are
ready to spray.
STARTING UP
4. Adjusting the pressure
a. Turn the Pressure Control Knob Clockwise to
increase pressure and counterclockwise to decrease
pressure.
b. Always use the lowest pressure necessary to
completely atomize the material.
Note: Operating the sprayer at higher pressure
than needed, wastes material, causes early tip
wear, and shortens sprayer life.
c. If more coverage is needed, use a larger tip rather
than increasing the pressure.
d. Check the spray pattern. The tip size and angle
determines the pattern width and flow rate.
Avoiding Tip Clogs
There is an easy way to keep the outside of the
tip clean from material build up:
Every time you stop spraying, for even a minute,
lock the gun and submerge it into a small bucket
of thinner suitable for the material sprayed.
Thinner will dissolve the buildup of paint on the
outside of tip, tip guard and gun much more
effectively if the paint doesn't have time to dry
out completely.
WARNING
Be sure to relieve pressure in the pump after
filling with Airlessco Pump Conditioner.
WARNING
Follow the "Pressure Relief Procedure".
To reduce the risk of injection, never
hold your hand, body, fingers or hand
in a rag in front of the spray tip when
cleaning or checking for a cleared tip.
Always point the gun toward the ground
or into a waste container when checking
to see if the tip is cleared or when using
a self-cleaning tip.
WARNING
When you spray into the paint bucket,
always use the lowest spray pressure
and maintain firm metal to metal contact
between gun and container.
5. When Shutting off the Sprayer
a. Whenever you stop spraying, even for a short break,
follow the "Pressure Relief Procedure".
b. Clean the tip & gun as recommended on page 11 for
Airlessco 008 gun or separate gun instruction manual for
all others.
c. Flush the sprayer at the end of each work day, if the
material you are spraying is water-based, or if it could
harden in the sprayer overnight. See "Flushing". Use a
compatible solvent to flush, then fill the pump and hoses
with an oil based solvent such as mineral spirits.
d. For long term shutdown or storage, refer to the
"Flushing" section of this manual.
To stop the unit in an emergency, turn the
motor off. Then relieve the fluid pressure
in the pump and hose as instructed in the
Pressure Relief Procedure.
9
PRESSURE RELIEF PROCEDURE
IMPORTANT!
To avoid possible serious body injury, always follow this procedure whenever the sprayer
is shut off, when checking it, when installing, changing or cleaning tips, whenever you stop
spraying, or when you are instructed to relieve the pressure.
1. Engage the gun safety latch. Refer to the separate
instruction manual provided with your gun on its
safety features and how to engage safety latch.
2. Turn the unit off & unplug it from the electrical outlet.
3. Disengage the gun safety latch and trigger the gun
to relieve residual fluid pressure.
Hold metal part of the gun in
contact with grounded metal pail.
USE MINIMUM PRESSURE !
4. Turn Prime/Pressure Relief Valve (PR Valve) to the open
(priming) position to relieve residual fluid pressure.
There will be a wider gap between valve handle and cam
body when in open position. In the closed position there is
only a very slight gap.
.
Note: The valve handle can move both clockwise
and counter clockwise and can face different directions.
5. Re-engage gun safety latch and
close Prime/Pressure Relief Valve.
If the SPRAY TIP OR HOSE IS CLOGGED, follow Step 1 through 5 above. Expect paint
splashing into the bucket while relieving pressure during Step 4.
If you suspect that pressure hasn't been relieved due to damaged Prime/Pressure Relief Valve
or other reason, engage the gun safety latch and take your unit to an authorized Airlessco
Service Center.
DAILY MAINTENANCE
1. Keep the displacement pump packing nut/wet cup lubricated with Airlessco TSO (Throat Seal Oil) at all times. The
TSO helps protect the rod and the packings.
2. Inspect the packing nut daily. Your pump has a patented Triple Life Packing System. Packing life will be extended a
minimum of three times if the following "Packing Adjustment" procedure is followed:
If seepage of paint into the packing nut and/or movement of the piston upward is found
(while not spraying), the packing nut should be tightened enough to stop leakage only, but
not any tighter. Overtightening will damage the packings and reduce the packing life.
10
SPRAY GUN OPERATION
SPRAY GUN
Attach spray gun to airless unit and tighten fittings securely.
Set the gun safety latch. (Also may be called gun safety lock,
or trigger lock)
* The gun safety latch should always be set when the gun is
not being triggered.
Read all warnings and safety precautions supplied with the
spray gun and in product manual.
MAJOR COMPONENTS OF SPRAY
GUN AND REVERSIBLE SPRAY TIP
™
Reversible
Spray Tip
Tip Guard
Trigger
Guard
Press up here and pull
gently to remove guard
™
Gun Safety
Latch or lock
Handle
(Filter Inside - unscrew
handle to access.)
SPRAY TIP ASSEMBLY
1. Be sure pressure relief procedure is followed before
assembling tip and housing to the gun.
2. Lock gun safety latch.
3. Insert REV-TIP™ cylinder into the REV-GUARD™
(guard housing assembly).
4. Guide metal seat into REV-GUARD™ (guard housing
assembly) through retaining nut & turn until it seats
against the cylinder.
5. Insert O-Ring gasket on metal seat so it fits in the grooves.
6. Finger tighten REV-GUARD™ retaining nut onto the gun.
7. Turn guard in the desired position.
8. Completely tighten the retaining nut.
TO REMOVE CLOGS FROM SPRAY TIP
1.
2.
3.
4.
Lock gun safety latch.
Turn REV-TIP™ handle 180 degrees.
Disengage trigger lock & trigger gun into pail.
If the REV-TIP™ handle appears locked (resists
turning), loosen the retaining nut. The handle will
now turn easily.
5. Engage gun safety latch & return handle to the
spray position.
Retaining Nut
P
Reverse to
Unplug
Spray Position Shown
CLEANING SPRAY GUN
Immediately after the work is finished, flush the gun out with
a solvent. Brush pins with solvent and oil them lightly so
they will not collect dried paint.
CLEANING FILTER IN GUN HANDLE
To clean the filter, use a brush dipped in an appropriate solvent. Change or clean filters at least once a day.
Some types of latex may require a filter change after
four hours of operation.
CLOGGED FLAT TIP
Should the spray tip become clogged, relieve pressure from
hose by following the "Pressure Relief Procedure." Secure
gun with the safety latch, take off guard, take out the tip,
soak in appropriate solvent & clean with a brush. (Do not
use a needle or sharp pointed instrument to clean the tip.
The tungsten carbide is brittle and can chip.)
11
AIRLESS SPRAY GUN TROUBLESHOOTING
Problem
Correction
Coarse Spray, Spotty Pattern
Pressure setting low
Irratic spray gun/hand motion
Increase pressure setting
Use a steady, parallel pass
Excessive Overspray (Fogging)
Pressure setting high
Paint over thinned/reduced/cut
Reduce pressure setting
Use less thinner/water/reducer
Spray Pattern Excessively Wide
Incorrect fan width selection
Select narrower fan width tip*
Spray Pattern Excessively Narrow
Incorrect fan width selection
Select wider fan width tip*
Excessive Paint Delivery
Paint Film Runs/Sags
Large tip orifice for application
Paint over thinned/reduced/cut
Excessive pressure
Spray gun/hand speed slow
Select smaller tip orifice*
Use less thinner/water/reducer
Reduce pressure setting
Increase pass speed
Spray Pattern Rounded and Heavy:
Pump Does Not Keep Up
Tip worn beyond use
Replace with new tip*
Spray Pattern Pulsates/Irratic:
Pump Does Not Keep Up
Pump worn or malfunctioning
Service pump
Thin or Spotty Coverage (Holidays)
Small tip orifice
Spray gun/hand speed fast
Select larger tip orifice*
Decrease pass speed
Thin Coverage in Center of Pattern
(Fingers)
Tip size larger than pump specs
Low pressure setting
Pump worn or malfunctioning
Replace with correct tip for pump*
Increase pressure setting
Service pump
Spray Pattern Irregular, Deflected
Tip orifice partialy clogged
Tip damaged
Clean tip carefully
Replace with new tip*
Excess Paint Builds on Tip Guard
Spray gun excessively close to
surface
Pressure setting high
Hold gun further from surface sprayed
Reduce pressure setting
Drips, Spits From Tip
Valve seat and/or ball in gun head
damaged or worn
Service spray gun, replace valve
assembly
Tip Clogs Continually
Debris in paint
Gun filter missing
Coarse filter mesh
Thouroughly strain paint before use
Insure gun filter is in handle
Use fine mesh filter in gun handle
Gun Filter Clogs Quickly
Debris in paint
Pump inlet strainer missing
Thouroughly strain paint before use
Do not operate without intlet strainer
*See “Tip Selection Guide” in this
manual
12
Cause
SPRAY TIP SELECTION
Spray tip selection is based on paint viscosity, paint type, and job needs. For light viscosities (thin paints),
use a smaller tip; for heavier viscosities (thicker paints), use a larger tip size.
Spray tip size is based on how many gallons of paint per minute can be sprayed through the tip. Do not
use a tip larger than the maximum pump flow rate or capacity the sprayer can accommodate. Pump flow
rate is measured in gallons per minute (GPM).
PATTERN WIDTH
Thickness of the paint coat per stroke is determined by spray tip "fan width", rate of the spray gun
movement, and distance to surface.
SPRAY TIP SELECTION
Two tips having the same tip size, but different pattern widths will deliver the same amount of paint
over a different area (wider or narrower strip). A spray tip with a narrow pattern width makes it easy to
spray in tight places.
SPRAY TIP REPLACEMENT
During use, especially with latex paint, high pressure will cause the orifice to grow larger. This destroys
the pattern.
Replace tips before they become excessively worn. Worn tips waste paint, cause overspray, make
cutting-in difficult, and decreases sprayer performance.
13
REV-TIP
TIP IDENTIFICATION:
TM
1st 3-digits identifies it as a REV-TIP for airless paint spraying (P.N.
560-xxx) or a REV-TIP for airless line striping (P.N. 562-xxxST).
TM
TM
SPRAY TIP SIZE CHART
For sizes not shown, call factory for availability.
Rev-Tip for Painting
4-6
6-8
8-10
10-12
12-14
14-16
16-18
20-24
102-152
152-203
203-254
254-305
305-356
356-406
406-457
508-610
.029
.009 .011 .013 .015 .017 .019 .021 .023 .025 .027 .031 .035 .039 .041
209 211 213
309 311 313
409 411 413
511 513
613
Gun Filter C= Coarse - 60 mesh
F
F
Wood
Interior
•
•
•
F= Fine - 100 mesh
Wood
Exterior
Masonry
Lacquer, Varnish
Stain, Sealer
Enamel
Exterior Stain
Vinyl, Acrylic, Latex
Vinyl, Oil Base Alkyd
Latex, Acrylic
Block Filler
Elastomer
221
321
421
521
621
721
819 821
NEW Wide Tips ► W21
215
315
415
515
615
715
815
217
317
417
517
617
717
F,C
C
•
•
•
•
•
•
•
219
319
419
519
619
C
C
•
•
•
•
•
•
•
•
Hi Build, Mil White
Ceiling
Structural Steel Heavy Coatings
225
325
425
525
625
227
327
427
527
627
229
335
431
531 535
631 635
831
639 641
739 741
W23 W25
REMOVE FILTER
C
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Water Flow Rate (gpm)
(water @ 2000psi, 138 bar)
(lpm)
.12
.49
.18
.69
.24
.91
.31
1.17
.38
1.47
.47
1.79
.57 .67
2.15 2.54
.77 1.03 1.31 1.63 1.80
2.96 3.90 4.98 6.17 6.81
Paint Flow Rate (gpm)
(latex paint @ 2000psi,
(lpm)
138 bar/1.36 spec. gr.)
.10
.38
.15
.57
.21
.79
.27
1.02
.33
1.25
.40
1.51
.49 .58
1.85 2.20
.66 .88 1.12 1.39 1.54
2.50 3.33 4.24 5.26 5.83
Pump Minimum
Output*
.25
1.0
.25
1.0
.33
1.25
.40
1.5
.50
1.9
.60
2.3
.75
2.8
(gpm)
(lpm)
*Pump will support tip worn to next larger size.
Rev-Tip for Striping
.009
.015
.011 .013
.017
.019
.021
1-2
25-51
2-4
4-6
6-8
51-102
215ST 217ST 219ST 221ST
102-152
152-203
315ST 317ST 319ST 321ST
1.0
3.8
1.25
4.7
1.5
5.7
2.0
7.5
2.2
8.2
.023
.025
.027
Latex
Latex
Latex
.031 .035
113ST 115ST 117ST 119ST
415ST 417ST 419ST 421ST
Striping Paint
Oil Base Oil Base Latex
REV-TIP
For Paint Spraying
P.N. 560-xxx
Includes Rev-Tip ,
Metal Seal & O-Ring Seal.
TM
Sample:
Latex
Latex
REV-TIP
TM
TM
1/2 Fan Width in Inches
560-517
REV-TIP Type
.88
3.3
STRIPING TIP - ORIFICE SIZE (Inches)
TM
Fan Width (6” from surface)
(mm)
in
14
223
323
423
523
623
Orifice Size in Thousandths
for Striping
Pavement & Turf
P.N. 562-xxxST
Includes Rev-TipTM, Metal Seal
& O-Ring Seal.
W!
NE Fine Finish REV-TIP
TM
Part # 571-xxx
Double orifice design for lower pressure spraying
when you need a smoother finish on interior trim,
cabinetry, shutters, and doors.
Fan Width
Inches (mm)
4-6 102-152
6-8 152-203
8-10 203-254
Orifice Size
.012 .014
212 214
312 314
412 414
Copyright © 2005, Airlessco by Durotech Co. All rights reserved.
(mm)
5th and 6th digits are for the orifice size and is measured in thousandths of an inch, e.g., 17 = 0.017 inch - The higher the number, the
larger the tip.
SPRAY TIP - ORIFICE SIZE (Inches)
TM
Fan Width (12” from surface)
in.
4th digit is the fan width - the number is half the fan width, e.g., 5
means a 10” fan. Exception are the“W” prefix tips which indicate a
wide spray pattern.
ELECTRIC MOTOR MAINTENANCE
1. LUBRICATION - This motor is supplied with prelubricated ball bearings, lubricated for life of bearing.
2. MOTOR BRUSHES - These need periodic inspection and replacement as wear indicates. Brush wear is greatly
influenced by individual application. It is recommended that brush wear be checked at early intervals of operation in
order to determine future required inspections. The standard brushes for this motor have an initial length of 13/16".
When the brushes are worn to a length of 1/4", they should be replaced.
3. TO CHANGE THE BRUSHES, follow the procedures below:
a. Unplug the machine.
b. Open the two covers at the rear of the motor.
c. Loosen the screw holding the brush terminal and remove the brush lead.
d. Push the brush retainer clip in and remove.
e. Remove the worn brushes (one on each side of motor).
f. Install new brushes in reverse order and replace covers.
NOTE: For longer life, new brushes (Part No. 331-778) need to have a run in period. After changing
brushes, set up the machine for spraying. Use a bucket of water and Airlessco Pump Conditioner mixture,
a 50 foot x 1/4" airless hose, airless gun with 0.017 tip on unit, turn the Prime/PR Control Valve to the
Prime position and turn the unit on. Turn the Pressure Control Knob to maximum pressure (fully CW
position) and let the pump cycle at high speed in the prime position for 20 minutes. This will allow the
brushes to "run in" properly giving a longer life.
15
FIELD TROUBLESHOOTING
PROBLEM
Unit doesn't prime
CAUSE
†Airleak due to:
• Loose Suction Nut
• Worn O-Rings
• Hole in Suction Hose
Unit primes but has no
or poor pressure
Unit does not maintain
good spraying pressure
Unit does not run
16
SOLUTION
• Tighten Suction Nut
• Replace O-Ring (106-011) on
suction seat, & O-Ring (106-020)
below suction seat
• Replace Suction Hose (331-290)
†Stuck or Fouled Balls
†Service outlet valve suction
assembly
†Pressure set too low
†Turn up pressure
†Filter(s) are clogged
†Clean or replace gun filter, inlet
filter and/or manifold filter
†Outlet Valve fouled/worn
†Service outlet valve
†Prime/Pressure Relief valve
bypassing
†Clean or replace primve valve
†Packings and/or piston worn
• Tighten packing nut
• Repack unit
†Blown spray tip
†Replace spray tip
†Packings and/or piston worn
†Repack unit
†Upper Seat worn
†Replace upper seat
†Blown fuse
†Replace fuse
• 15A SlowBlow (pn. 331-256)
†Electrical failure
†See electrical troubleshooting
GEAR AND PUMP ASSEMBLY
- Do not operate
FIGURE 12
machine without cover guard in place.
Part Number
331-234
331-046
331-038
331-406
331-047
331-040
100-381
100-380
331-088
331-065
331-117
331-062
331-209
100-318
331-074
331-111
331-061
115-019
Description
Cover
Bearing
Crosshead Assembly
Gear Crank
Bearing
Gearbox Casting *
Bolt Soc Hd (2)
Shoulder Bolt (2)
Retaining Ring
Pin
Sleeve
Retaining Spring
Fluid Pump Ass’y
Screw (2)
Tube Spacer (2)
Cover Guard
Sleeve Bearing
Hose Connector (1/4 NPSXNPT)
GEARBOX SLEEVE
BEARING REPLACEMENT
1
2
3
NOTE: When replacing item (1),
cover outside of sleeve with clear silicone
prior to inserting into cover assembly.
Servicing Gear Box Assembly
1. Remove fluid pump as per "Fluid Pump Disconnect"
procedures.
2. Remove frame from the gearbox by loosening the four
mounting screws.
3. Refer to Figure 12. Separate cover assembly from box
by removing bolts from front of cover & back of box &
shoulder bolts from front of cover & back of box.
4. Lay unit on its back and disassemble gearbox.
5. Inspect bearings, Crosshead Assembly, Gearcrank & sleeve
bearing inside cover assembly for wear/damage. Replace
worn/damaged parts.
6. If gear grease needs replacing, replace with gear grease
(Part No. 331-132).
7. Clean mating surfaces of cover and box thoroughly. Use
Part No. 105-331 BLUE XS™ ADVANCED RTV
SILICONE INSTANT GASKET.
8. Reassemble in reverse order.
FIGURE 10 PARTS LIST
ITEM #
PART #
DESCRIPTION
1
331-061 Sleeve Bearing
2
331-103 Washers (2)
3
331-197 Screws (2)
17
SERVICING THE FLUID PUMP
NOTE: Check everything in the Troublshooting Chart before disassembling the Fluid Pump.
Fluid Pump Removal - Refer to Figure 11
1. Follow the Pressure Relief Procedure page 10.
2. Flush the material you are spraying out of the machine.
3. Remove the connecting rod shield (331-111).
4. Move the piston rod (331-093) to its lowest position by cycling pump slowly or by rotating the motor fan.
5. Remove the grey wire from the Pressure Control Switch.
6. Remove the retaining ring (331-062) from the connecting rod (331-038) and slide the sleeve (331-117)
down revealing the connecting rod pin (331-065).
7. Remove the suction assembly from the fluid pump body (331-011) by unscrewing the suction nut (331-034)
with the packing adjustment tool.
8. Using a 1/2” wrench unscrew the two bolts (100-318) from the cover assembly 331-234). The fluid pump
will be hanging loosely at this point.
9. Remove the connecting rod pin (331-065) out of the connecting rod (331-038), allowing the removal of the
fluid pump (331-209) from the machine.
FIGURE 11
18
SERVICING THE FLUID PUMP
Fluid Pump Reinstallation Refer to Figure 11 & 14
1. Loosen the packing nut and ensure that the piston rod (331-093) is in its upper position in the fluid pump
body (331-011). Slip the sleeve (331-117) & the retaining ring (331-062) over the piston rod.
2. Push the piston rod up into the connecting rod (331-038) & align the holes. Insert the connecting rod pin
(331-065) through the connecting rod & piston. Slip the sleeve over the connecting rod pin and insert the
retaining ring into the groove on the connecting rod.
3. Push the two bolts (100-318) through the tube spacers (331-074) & screw them into the cover assembly (331234). Using a 1/2” wrench, tighten the two bolts evenly (alternating between them) until you reach 20 ft-lbs.
4. Reassemble the lower suction valve assembly by placing the suction seat assembly: O-ring (106-011),
suction ball (331-030) and suction ball guide (331-029) in the suction nut (331-034) and screw onto the fluid
pump body.
5. Reconnect the grey wire to the Pressure Control Switch.
6. Start the machine and operate slowly to check the piston rod for binding. Adjust the two bolts, holding the
fluid pump body to the cover assembly, if necessary. This will eliminate any binding.
7. Tighten the packing nut counter clockwise until resistance is felt against the Belleville Springs, then go
3/4 of a turn more. Put five drops of Airlessco Throat Seal Oil into the packing nut.
8. Run the machine at full pressure for several minutes. Release the pressure by following the Pressure Relief
Procedure & readjust the packing nut per step 7 above.
9. Install the connecting rod shield (331-111) so that the small hole is in the upper right hand corner.
19
Servicing the Piston Rod - Outlet Valve
DISASSEMBLY OF THE OUTLET VALVE
REFER TO FIGURE 13
1. Disconnect the Fluid Pump.
2. Place piston holder (Item 1) in a vise. Slide piston into
the holder & lock in place with a 3/8” dowel (Item2).
3. Use a 1/4” allen wrench to unscrew the outlet seat retainer
(Item 7) from the piston.
4. Remove the outlet seat (Item 5), O-ring (Item 6) and
outlet ball (Item 4).
5. Inspect outlet ball & seat for wear. Replace as necessary.
6. While piston is still locked in the holder, install parts
back into the piston in the following order:
Piston
1
Figure 13
2
ball, outlet seat and O-ring
Before reinstalling the outlet seat retainer, apply two drops of
Loctite No. 242 (blue) on the threads & torque to 20 ft-lbs.
Item Part Number
3
Description
1
331-195
Piston Holder
2
331-196
3/8” Dowel
4
3
331-708
Piston
6
4
331-027
Outlet Ball
5
331-026
Outlet Seat
6
331-100
O-ring
7
331-314
Outlet Seat Retainer
5
7
Servicing the Suction Assembly
Refer to Figure 14
1. Unthread and remove suction nut from the fluid pump body.
2. Remove suction seat (Item 5), O-ring (Item 4), suction ball
(Item 3) and suction retainer (Item 2).
3. Clean all parts and inspect them for wear or damage, replacing
parts as needed.
4. Clean inside of the fluid pump body.
5. Reassemble lower suction valve assembly by placing the
suction seat (Item 5), O-ring (Item 4), suction ball (Item 3)
& suction ball guide (Item 2) in the suction nut (Item 6) &
screw onto fluid pump body.
Item Part Number
20
Figure 14
1
2
3
Description
1
331-011
Fluid Pump Body
2
331-029
Suction Ball Guide
3
331-030
Suction Ball
4
106-011
O-ring
5
331-409
Suction Seat
6
331-034
Suction Nut
4
5
6
Packing Replacement Procedures
Replacement Instructions:
Fluid Pump Removal - Refer to Figure 11
Disassembly of the Fluid Pump - Figure 16
* Second spring, curve facing up
(
1. Unscrew & remove the packing nut (331-037).
* Third spring, curve facing down
2. Push the piston rod (331-708) down through the
packings & out of the pump.
9. Take upper male gland (331-022) & place it rounded side
up.
3. Now push the packing removal tool (187-249) up
through the pump & remove from the top bringing
packings, spacer & springs along with it, leaving fluid
body (331-011) empty.
10. Take three upper polyethylene packings (331-023) & two
leather packings (331-307) & assemble with inverted side
down
, on to the male gland in the following order:
*Make sure all old packings & glands have been
removed from fluid pump.
11. Take upper female gland (331-021) & place on top of the
assembled upper packings with the inverted side down.
4. Clean inside of fluid body (331-011).
5. Disassemble all parts & clean for reassembly. Discard
any old packings.
6. Lubricate leather packing in lightweight oil for 10
minutes prior to reassembly.
Disassembly of the Outlet Vavle - Figure 13
1. Follow steps 2-6 on page 19 under Disassembly of
the Outlet Valve.
REASSEMBLY - Figure 15 & 16
1. Take lower male gland (331-014) & place it down on
the flat side.
2. Take three of the lower polyethylene packings (331016) & two of the leather packings (331-306) & place
onto the male gland in the following order with the
inverted side down :
(
* First spring, curve facing down
(
1. Follow steps 1-9 on page 16 under Removal
procedures.
8. Take three Belleville Springs (331-025) & slide over the top
of the piston in the following order:
polyethylene, leather, polyethylene, leather, polyethylene.
12. Take assembled upper glands & packings (7 pieces) & slide
on over the top of the piston, making sure inverted sides are
down.
13. Take the packing holder (331-019) & replace the white
O-ring (106-009) & the black O-ring (106-010) with new
ones from the packing kit.
14. Slide the packing holder over the top of the upper packings
so they fit inside.
15. Lubricate inside of the fluid pump body & the outside of
the packings with a light weight oil.
16. Slide completed assembly into fluid pump body (331-011).
* To keep packings secured in correct position, hold
the pump body upside down & push the completed
assembly upwards into the pump body. Once placed
inside, tilt pump body back up to keep all pieces in.
3. Take the female adaptor (331-305), which is inverted
on both sides
, & place it on top of your
assembled lower packings.
17. Tighten packing nut (331-037) onto the top of the fluid
pump body & tighten until you feel slight resistance against
the Belleville Springs (331-025). Using the Packing
Adjustment Tool (189-211), tighten another 3/4 of a turn.
4. Follow step 2 above with your packings inverted side
up.
1. Follow steps 1-9 on page 16 under reinstallation prcedures.
polyethylene, leather, polyethylene, leather, polyethylene.
Fluid Pump Reinstallation - Figure 11 & 14
5. Take the second lower male gland and place it on top
of your assembled packings with the rounded side
down.
6. Take assembled glands & packings (13 pieces) & slide
on to the lower half of the piston.
7. Take the spacer (331-018) & slide over the top of the
piston (it doesn’t matter which direction it sits), falling
onto lower packings.
21
Packing Replacement Procedures (Continued)
FIGURE 15
FIGURE 16
22
FRAME ASSEMBLY Part Number 331-401
FIGURE 17
22
Item
1
2
3
4
5
6
7
8
9
10
11
Part #
331-234
331-143
119-048
331-490
331-212
331-213
117-090
301-191
331-398
301-405
331-838
Description
Cover
Frame
Screw (4)
.6 HPDC Motor
Fan
Fan Cover
Fan Cover Screws (3)
Fan Retaining Clip
Motor Brush (2)
Blank Plate
Terminal Box
Item
12
13
14
15
16
17
18
19
20
21
22
Part #
111-037
100-382
100-028
331-048
100-180
100-318
115-019
331-725
331-111
331-074
100-638
Description
Screw (4)
Screw (2)
Plug 1/4 NPT
Rubber Boot (2)
Prime P/R Valve
Screw (2)
Hose Connector (1/4 NPSXNPT)
Pressure Valve
Shield
Tube Spacer (2)
Terminal Box Gasket
23
SUCTION ASSEMBLIES Part Number 331-238
FIGURE 18
Item
1
2
3
4
5
6
7
8
9
10
24
Part
Number
331-217
331-135
331-290
331-425
111-016
331-231
331-090R
331-035
331-034
106-020
Description
Inlet Strainer
Spring Clip
Suction Hose Ass’y (Inc. strainer)
Bypass Hose
Nylon Tie
Bypass Hose Ass’y
Fitting
Suction Elbow
Suction Nut
O-Ring PTFE
TROUBLESHOOTING - Machine does not start
Refer to Figure 19
CAUSE
STEPS
Control Settings
STEP 1: After making sure that the machine is plugged into the wall, verify that the
on-off switch is in the ON position and that the pressure control knob is turned all the
way to the right (clockwise for maximum pressure).
Fuse
STEP 2: Using your multi-meter, test the fuse for continuity or replace with a new
fuse. If the fuse reads good, move on to step three.
Power Source
STEP 3: Locate the L1 and L2 terminals on the board, and then using your multi-meter check to make sure you have 110 volts AC across the two terminals (the cord wires
will still be attached). If there is no voltage at these leads, there is no power getting
to the machine. Check your power source (outlet, circuit breaker, extension cord, and
power cord). If you have AC voltage at the L1 and L2 terminals, go to step 4.
Thermal Overload
STEP 4: Disconnect the two red motor leads (S1 & S2) and test for continuity between
them. No continuity means that the thermal coupler has opened due to excessive motor
heat. If the motor is still hot to the touch, allow it to cool and then retest. If the motor is
cool and there is not continuity on the red leads, contact your local electric motor repair
facility to repair/replace the thermal coupler. Continuity shows that the motor's thermal
coupler has not tripped. Proceed to step 5.
Pressure Control Assembly
(Board)
STEP 5: If everything checks out in steps one through four and the power indicating
light is still out, replace the pressure control assembly.
25
ELECTRICAL BOARD CALIBRATION
Note: Anytime a sensor, pressure control assembly (board) or both are replaced,
the following calibrations must be performed.
PRESSURE CALIBRATION
1. Attach a 50', 1/4" airless hose, airless gun with 0.017 tip and a 5000 psi glycerin filled pressure gauge to
the pump.
2. Place the suction tube into a bucket of Airlessco Pump Conditioner and water.
3. Turn prime/pressure relief valve to the prime (open) position and prime fluid pump.
4. Place the prime/pressure relief valve in the pressure (closed) position.
5. Slowly increase pressure using the control knob, while watching the glycerin guage. Maximum pressure
is to be 3000 psi. Adjust pressure using the set screw under label on top of pressure control knob.
Clockwise to increase pressure and counter-clockwise to decrease pressure. Trigger the gun a few times to
ensure maximum pressure is correct.
6. If pressure exceeds 3000 psi, use adjusting set screw under the label on the knob top. Turning the set screw
counter-clockwise will decrease the unit pressure.
REPLACEMENT OF ELECTRICAL COMPONENTS
Always unplug the electrical cord before servicing machine.
NOTE: Anytime the pressure control assembly, sensor or both are replaced, perform the calibrations.
PRESSURE CONTROL ASSEMBLY (Electrical Control Board)
1. Unplug machine's power cord.
2. Remove four screws (Fig. 17, Item 12) from pressure control assembly.
3. Disconnect all leads from pressure control assembly.
4. Reassemble in reverse order.
PRESSURE CONTROL KNOB
1. Unplug machine's power cord.
2. Remove four screws (Fig. 17, Item 12) from pressure control assembly.
3. Disconnect Pressure Control Knob wire from pressure control assembly.
4. Unscrew Knob from Fluid Body fitting
4. Reassemble in reverse order, use liquid pipe thread sealer (PST) on threads, tighten to snug, then rotate 90 deg so wire is
tucked next to fluid body. Do Not Overtighten.
ON-OFF TOGGLE SWITCH
1. Lower the pressure control assembly as described above.
2. Disconnect the two wires on the switch.
3. Use a 9/16" wrench to loosen the nut on the toggle switch shaft.
4. Reassemble in reverse order.
FUSE HOLDER
1. Lower pressure control assembly as described above.
2. Disconnect the two wires on the holder.
3. Remove holder cover and fuse.
4. Use 11/16" wrench to remove the nut from the holder shaft.
5. Reassemble in reverse order.
26
ELECTRICAL SYSTEM
FIGURE 19
Item
Part #
Description
1
331-168
Electrical Power Cord
2
331-185
Strain Relief
3
331-138
Screw
4
331-312
Fuse Holder
5
331-256
Fuse 15A Slow Blow
6
331-311
Toggle Switch
7
331-490
Motor .6HP 90VCD
8
331-749
Pressure Control Assembly
9
331-725
Pressure Control Switch
27
NOTES
28
NOTES
29
AIRLESSCO BY DUROTECH CO.
5397 N. Commerce Ave., Moorpark, CA 93021
Tel: 805-523-0211 Fax: 805-523-1063
www.airlessco.com
eMail: [email protected]
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